U.S. patent number 10,061,329 [Application Number 15/657,611] was granted by the patent office on 2018-08-28 for flow control system for a tubular.
This patent grant is currently assigned to BAKER HUGHES, A GE COMPANY, LLC. The grantee listed for this patent is Stephen Coulston. Invention is credited to Stephen Coulston.
United States Patent |
10,061,329 |
Coulston |
August 28, 2018 |
Flow control system for a tubular
Abstract
A flow control system for a downhole system includes a tubular
having an outer surface, an inner surface defining a flow path, and
at least one cavity defined between the outer surface and the inner
surface. A first opening formed in the outer surface fluidically
connected with the at least one cavity, a second opening formed in
the inner surface fluidically connecting the at least one cavity
with the flow path. At least one impeller rotatably mounted in the
at least one cavity, and a flow control device operatively coupled
to the impeller, the flow control device selectively adjusting a
rotational impedance of the at least one impeller to control fluid
flow between the first opening and the second opening.
Inventors: |
Coulston; Stephen (Houston,
TX) |
Applicant: |
Name |
City |
State |
Country |
Type |
Coulston; Stephen |
Houston |
TX |
US |
|
|
Assignee: |
BAKER HUGHES, A GE COMPANY, LLC
(Houston, TX)
|
Family
ID: |
63208238 |
Appl.
No.: |
15/657,611 |
Filed: |
July 24, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B
41/0085 (20130101); E21B 34/101 (20130101); G05D
11/008 (20130101); E21B 34/08 (20130101); G05D
7/018 (20130101); G05D 7/0676 (20130101); E21B
43/126 (20130101) |
Current International
Class: |
E21B
34/08 (20060101); E21B 34/10 (20060101); G05D
11/00 (20060101); G05D 7/01 (20060101); E21B
43/12 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Mircea Eremia, Mohammad Shahidehpour; "Handbook of Electrical Power
System Dynamics: Modeling, Stability, and Controlo;" Book; 2004; p.
590; section 3.6.32 The Actuator; Published by Wiley-IEEE Press.
cited by applicant.
|
Primary Examiner: Buck; Matthew R
Attorney, Agent or Firm: Cantor Colburn LLP
Claims
The invention claimed is:
1. A flow control system for a downhole system comprising: a
tubular including an outer surface, an inner surface defining a
flow path, and at least one cavity defined between the outer
surface and the inner surface; a first opening formed in the outer
surface fluidically connected with the at least one cavity; a
second opening formed in the inner surface fluidically connecting
the at least one cavity with the flow path; at least one impeller
rotatably mounted in the at least one cavity; and a flow control
device operatively coupled to the impeller, the flow control device
being selectively controlled to adjust a rotational impedance of
the at least one impeller to control fluid flow between the first
opening and the second opening.
2. The flow control system according to claim 1, wherein the at
least one cavity includes a first cavity fluidically connected to
the first opening and the second opening housing the at least one
impeller and a second cavity housing the flow control device.
3. The flow control system according to claim 1, wherein the flow
control device comprises a generator operatively connected to an
electrical load.
4. The flow control system according to claim 3, wherein the
electrical load comprises one or more resistors electrically
connected in parallel with one or more switches.
5. The flow control system according to claim 4, further
comprising: a controller operatively connected to the one or more
switches, the controller activating at least one of the one or more
switches to bypass a corresponding one of the one or more resistors
to adjust an electrical load on the generator.
6. The flow control system according to claim 4, wherein the one or
more switches comprise one or more transistors.
7. The flow control system according to claim 3, wherein the
electrical load comprises a switch electrically connected in series
with at least one resistor.
8. The flow control device according to claim 7, wherein the switch
comprises a transistor.
9. The flow control system according to claim 8, further
comprising: a controller operatively connected to the transistor,
the controller selectively controlling a resistance of the
transistor to control current flow through the resistor to adjust
an electrical load on the generator.
10. A resource exploration and recovery system comprising: a
surface system; and a downhole system operatively and fluidically
connected to the surface system, the downhole system including a
string of tubulars including a flow control system, at least one
tubular of the string of tubulars includes a tubular having an
outer surface, an inner surface defining a flow path, and at least
one cavity defined between the outer surface and the inner surface;
a first opening formed in the outer surface fluidically connected
with the at least one cavity; a second opening formed in the inner
surface fluidically connecting the at least one cavity with the
flow path; at least one impeller rotatably mounted in the at least
one cavity; and a flow control device operatively coupled to the
impeller, the flow control device being selectively controlled to
adjust a rotational impedance of the at least one impeller to
control fluid flow between the first opening and the second
opening.
11. The resource exploration and recovery system according to claim
10, wherein the flow control device comprises a generator
operatively connected to an electrical load.
12. The resource exploration and recovery system according to claim
11, wherein the electrical load comprises one or more resistors
electrically connected in parallel with one or more switches.
13. The resource exploration and recovery system according to claim
12, further comprising: a controller operatively connected to the
one or more switches, the controller activating at least one of the
one or more switches to bypass a corresponding one of the one or
more resistors to adjust an electrical load on the generator.
14. The resource exploration and recovery system according to claim
11, wherein the electrical load comprises a switch electrically
connected in series with at least one resistor.
15. The resource exploration and recovery system according to claim
14, further comprising: a controller operatively connected to the
switch, the controller selectively controlling a resistance of the
switch to control current flow through the resistor to adjust an
electrical load on the generator.
Description
BACKGROUND
Downhole systems employ various devices to control fluid flow. In
some cases, it may be desirable to induce a pressure drop in fluid
flowing from an annulus into downhole tubing. In such cases, fluid
is typically directed through a labyrinth or convoluted passage.
Pressure drops/changes may be controlled by adjusting a length of
the convoluted passage. Typically, a tool is run downhole and
connected to a valve actuator. The valve actuator is shifted to
change a length of the convoluted passage in order to achieve a
selected pressure drop. In other cases, an electrical actuator may
be employed to adjust the length of the convoluted passage. In
either case, adjusting a length of the convoluted passage requires
a significant input force.
SUMMARY
A flow control system for a downhole system includes a tubular
having an outer surface, an inner surface defining a flow path, and
at least one cavity defined between the outer surface and the inner
surface. A first opening formed in the outer surface fluidically
connected with the at least one cavity. A second opening formed in
the inner surface fluidically connecting the at least one cavity
with the flow path. At least one impeller rotatably mounted in the
at least one cavity; and a flow control device operatively coupled
to the impeller, the flow control device selectively adjusting a
rotational impedance of the at least one impeller to control fluid
flow between the first opening and the second opening.
A resource exploration and recovery system includes a surface
system, and a downhole system operatively and fluidically connected
to the surface system, the downhole system includes a string of
tubulars including a flow control system, at least one tubular of
the string of tubulars includes a tubular having an outer surface,
an inner surface defining a flow path, and at least one cavity
defined between the outer surface and the inner surface. A first
opening formed in the outer surface fluidically connected with the
at least one cavity. A second opening formed in the inner surface
fluidically connecting the at least one cavity with the flow path.
At least one impeller rotatably mounted in the at least one cavity
and a flow control device operatively coupled to the impeller, the
flow control device selectively adjusting a rotational impedance of
the at least one impeller to control fluid flow between the first
opening and the second opening.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered
alike in the several Figures:
FIG. 1 depicts a resource exploration and recovery system including
a tubular having a flow control system, in accordance with an
exemplary embodiment;
FIG. 2 depicts a cross-sectional view of the flow control system of
FIG. 1;
FIG. 3 depicts a control system for the flow control system, in
accordance with an aspect of an exemplary embodiment;
FIG. 4 depicts an electronics module of the control system, in
accordance with an aspect of an exemplary embodiment; and
FIG. 5 depicts an electronics module of the control system, in
accordance with another aspect of an exemplary embodiment.
DETAILED DESCRIPTION
A resource exploration and recovery system, in accordance with an
exemplary embodiment, is indicated generally at 2, in FIG. 1.
Resource exploration and recovery system 2 should be understood to
include well drilling operations, resource extraction and recovery,
CO.sub.2 sequestration, and the like. Resource exploration and
recovery system 2 may include a surface system 4 operatively and
fluidically connected to a downhole system 6. Surface system 4 may
include pumps 8 that aid in completion and/or extraction processes
as well as fluid storage 10. Fluid storage 10 may contain a gravel
pack fluid or slurry (not shown) or other fluid which may be
introduced into downhole system 6. Surface system 4 may also
include a control system 12 that may monitor and/or activate one or
more downhole operations.
Downhole system 6 may include a downhole string 20 formed from a
plurality of tubulars, one of which is indicated at 21 that is
extended into a wellbore 24 formed in formation 26. Wellbore 24
includes an annular wall 28 that may be defined by a wellbore
casing 29 provided in wellbore 24. Of course, it is to be
understood, that annular wall 28 may also be defined by formation
26. Downhole string 20 may include a flow control system 34
operatively associated with a tubular 37 of one of the plurality of
tubulars 21.
With reference to FIG. 2, tubular 37 includes an outer surface 40
and an inner surface 42 defining a flow path 44. A first opening 48
is formed in outer surface 40 and a second opening 50 is formed in
inner surface 42. A first cavity 54 is formed between outer surface
40 and inner surface 42. First cavity 54 is fluidically connected
with first opening 48 and second opening 50. Specifically, fluids
may pass through first cavity 54 from wellbore 24 into flow path 44
or fluids may flow from flow path 44 to wellbore 24 through first
cavity 54. A second cavity 56 is arranged between outer surface 40
and inner surface 42.
In accordance with an exemplary embodiment, a first impeller 60 is
rotatably arranged in first cavity 54. A second impeller 62 may
also be arranged in first cavity 54. The number of impellers
arranged in first cavity 54 may vary. First and second impeller 60
and 62 are rotatably supported by a shaft 64 that may extend into
second cavity 56. Shaft 64 is operatively connected with a flow
control device 68 that controls a resistance to rotation of shaft
64.
In accordance with an aspect of an exemplary embodiment, flow
control system 34 may include a generator 72 and an electrical load
74. It should be understood that flow control system 34 may take on
a variety of forms including clutches and other mechanisms that may
impede rotation of shaft 64. Generator 72 may be coupled to first
and second impellers 60 and 62 through shaft 64. Electrical load 74
may be electrically coupled to an output of generator 72. A
controller 80 may be operatively connected with electrical load 74.
It should be understood that controller 80 may draw part or all of
its power from generator 72.
As shown in FIG. 3, controller 80 may include a processor 82, a
non-volatile memory 84 and a power supply 87. Controller 80 may
receive control inputs through a control input device 90 to
selectively adjust electrical load 74. By adjusting electrical load
74, rotational speed of shaft 64 imparted by impellers 60 and/or 62
may be selectively controlled. In this manner, fluid flow through
first cavity 54 may be controlled to establish a selected pressure
drop. Controller 80 may also include a control output device 94
that provides data allowing flow control system 34 to achieve a
selected load balance on generator 72.
In accordance with an exemplary aspect, controller 80 may adjust a
resistance of electrical load 74. With reference to FIG. 4,
electrical load 74 may include a plurality of resistors 104
including a first resistor 106, a second resistor 108 and a third
resistor 110. Electrical load 74 may also include a plurality of
switches 112. Each of the plurality of switches 112 may be
electrically connected in parallel with a corresponding one of the
plurality of resistors 104. For example, a first switch 114 may be
connected in parallel with first resistor 106, a second switch 116
may be connected in parallel with second resistor 108 and a third
switch 118 may be connected in parallel with third resistor 110.
Each switch 114, 116, and 118 may be selectively closed according
to control signals from controller 80 to short a corresponding one
of resistors 104 to establish a selected electrical load on
generator 72. In an embodiment, each of the plurality of switches
112 comprises a transistor. It should be understood that there are
various other methodologies for creating an electrical load. The
above described methodology for creating a load is exemplary.
FIG. 5 depicts electrical load 74 in accordance with another aspect
of an exemplary embodiment. Electrical load 74 includes a resistor
130 electrically connected in series with a selectively adjustable
switch 134. Selectively adjustable switch 134 may take the form of
a transistor. In operation, controller 80 may control selectively
adjustable switch 134 to establish a desired current flow through
resistor 130. The selected current flow establishes a desired
electrical load on generator 72. By selectively controlling an
electrical load at an output of generator 72, rotation of shaft 64
may be selectively impeded (or unimpeded) to control rotation of
first and/or second impeller 60, 62. Control of first and/or second
impellers 60, 62 may control fluid flow through first cavity 54 to
establish a desired pressure drop between first opening 48 and
second opening 50.
Set forth below are some embodiments of the foregoing
disclosure:
Embodiment 1
A flow control system for a downhole system including a tubular
including an outer surface, an inner surface defining a flow path,
and at least one cavity defined between the outer surface and the
inner surface. A first opening formed in the outer surface
fluidically connected with the at least one cavity. A second
opening formed in the inner surface fluidically connecting the at
least one cavity with the flow path. At least one impeller
rotatably mounted in the at least one cavity; and a flow control
device operatively coupled to the impeller, the flow control device
selectively adjusting a rotational impedance of the at least one
impeller to control fluid flow between the first opening and the
second opening.
Embodiment 2
The flow control system according as in any prior embodiment,
wherein the at least one cavity includes a first cavity fluidically
connected to the first opening and the second opening housing the
at least one impeller and a second cavity housing the flow control
device.
Embodiment 3
The flow control system as in any prior embodiment, wherein the
flow control device comprises a generator operatively connected to
an electrical load.
Embodiment 4
The flow control system as in any prior embodiment, wherein the
electrical load comprises one or more resistors electrically
connected in parallel with one or more switches.
Embodiment 5
The flow control system as in any prior embodiment, further
comprising: a controller operatively connected to the one or more
switches, the controller activating at least one of the one or more
switches to bypass a corresponding one of the one or more resistors
to adjust an electrical load on the generator.
Embodiment 6
The flow control system as in any prior embodiment, wherein the one
or more switches comprise one or more transistors.
Embodiment 7
The flow control system as in any prior embodiment, wherein the
electrical load comprises a switch electrically connected in series
with at least one resistor.
Embodiment 8
The flow control device as in any prior embodiment, wherein the
switch comprises a transistor.
Embodiment 9
The flow control system as in any prior embodiment, further
comprising: a controller operatively connected to the transistor,
the controller selectively controlling a resistance of the
transistor to control current flow through the resistor to adjust
an electrical load on the generator.
Embodiment 10
A resource exploration and recovery system including a surface
system, and a downhole system operatively and fluidically connected
to the surface system, the downhole system including a string of
tubulars including a flow control system, at least one tubular of
the string of tubulars includes a tubular having an outer surface,
an inner surface defining a flow path, and at least one cavity
defined between the outer surface and the inner surface. A first
opening formed in the outer surface fluidically connected with the
at least one cavity. A second opening formed in the inner surface
fluidically connecting the at least one cavity with the flow path.
At least one impeller rotatably mounted in the at least one cavity
and a flow control device operatively coupled to the impeller, the
flow control device selectively adjusting a rotational impedance of
the at least one impeller to control fluid flow between the first
opening and the second opening.
Embodiment 11
The resource exploration and recovery system as in any prior
embodiment, wherein the flow control device comprises a generator
operatively connected to an electrical load.
Embodiment 12
The resource exploration and recovery system as in any prior
embodiment, wherein the electrical load comprises one or more
resistors electrically connected in parallel with one or more
switches.
Embodiment 13
The resource exploration and recovery system as in any prior
embodiment, further comprising: a controller operatively connected
to the one or more switches, the controller activating at least one
of the one or more switches to bypass a corresponding one of the
one or more resistors to adjust an electrical load on the
generator.
Embodiment 14
The resource exploration and recovery system as in any prior
embodiment, wherein the electrical load comprises a switch
electrically connected in series with at least one resistor.
Embodiment 15
The resource exploration and recovery system as in any prior
embodiment, further comprising: a controller operatively connected
to the switch, the controller selectively controlling a resistance
of the switch to control current flow through the resistor to
adjust an electrical load on the generator.
The use of the terms "a" and "an" and "the" and similar referents
in the context of describing the invention (especially in the
context of the following claims) are to be construed to cover both
the singular and the plural, unless otherwise indicated herein or
clearly contradicted by context. Further, it should further be
noted that the terms "first," "second," and the like herein do not
denote any order, quantity, or importance, but rather are used to
distinguish one element from another. The modifier "about" used in
connection with a quantity is inclusive of the stated value and has
the meaning dictated by the context (e.g., it includes the degree
of error associated with measurement of the particular
quantity).
The teachings of the present disclosure may be used in a variety of
well operations. These operations may involve using one or more
treatment agents to treat a formation, the fluids resident in a
formation, a wellbore, and/or equipment in the wellbore, such as
production tubing. The treatment agents may be in the form of
liquids, gases, solids, semi-solids, and mixtures thereof.
Illustrative treatment agents include, but are not limited to,
fracturing fluids, acids, steam, water, brine, anti-corrosion
agents, cement, permeability modifiers, drilling muds, emulsifiers,
demulsifiers, tracers, flow improvers etc. Illustrative well
operations include, but are not limited to, hydraulic fracturing,
stimulation, tracer injection, cleaning, acidizing, steam
injection, water flooding, cementing, etc.
The term "about" is intended to include the degree of error
associated with measurement of the particular quantity based upon
the equipment available at the time of filing the application. For
example, "about" can include a range of .+-.8% or 5%, or 2% of a
given value.
While one or more embodiments have been shown and described,
modifications and substitutions may be made thereto without
departing from the spirit and scope of the invention. Accordingly,
it is to be understood that the present invention has been
described by way of illustrations and not limitation.
* * * * *